Hobart 500574 Owner's manual

Hobart
Brand
Hobart
Model
500574
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Outperforms the competition on arc
quality, voltage control and value.
Whether you’re a professional or just want to weld like
one, the IronMan 240 is unmatched in its class. It delivers
30 to 280 amps of pure power with an arc optimized to
deliver a flawless weld, making spatter and post-weld cleanup
almost nonexistent. Weld as thin as 24 gauge up to 1/2 inch
(13 mm) mild steel.
The dual-geared wire drive system with aluminum housing
delivers 50 to 700 ipm wire feed speed.
Reversible drive roll (two grooves for two wire sizes on one
drive roll) decreases spare parts and changeover time.
Easy to set and adjust for different materials and thicknesses
— features infinite voltage and wire feed for finer control,
less spatter and cleaner welds.
Applications
Maintenance/repair Auto body Manufacturing
Construction Farm/ranch Metal art
Offers easier fine control of the output parameters for improved arc performance with less spatter for a better bead
appearance and less clean up.
Spool guns enhance feedability and reduce “bird-nesting” associated with soft aluminum wires. No additional control box
or adapter is required to connect the SpoolRunner™ 200 spool gun.
Experience smooth, spatter-free starts — the run-in feature automatically slows the wire feed speed to a pre-set speed
prior to arc initiation, improving arc starts.
50 percent less stocking of drive rolls. Standard one-piece drive roll decreases spare parts and changeover time,
reducing overall costs.
Changing wire spools is a snap with the toolless brake tension knob.
Provides easy access for spool and drive roll changes, increasing productivity and operator appeal.
Cooling system operates only when needed reducing power consumption and contaminants drawn into the machine.
Five-year warranty on transformers, stabilizers and main rectifiers; three years on generators, PC boards and drive systems;
and one year on guns (MIG, plasma and TIG torches).
Infinite voltage and wire feed
Spool gun ready
Run-in technology
Reversible drive roll (two grooves for
two wire sizes on one drive roll)
Spool hub assembly accommodates
2-, 10-, 33- and 45-pound spools
Hinged door panel
Fan-On-Demand™
Hobart 5/3/1 industrial warranty
Features Benefits
Includes
15 ft. (4.6 m) MIG gun
10 ft. (3 m) work cable with clamp
Power cord with plug
Regulator/flow gauge with
5 ft. (1.5 m) gas hose
.030 and .035 in. contact tips
Dual-groove .030/.035 in. drive roll
Built-in running gear/cylinder rack
IronMan™ 240
Complete Single-Phase MIG Welding Package 287788
Dec. 2020
500574
Spool
Gun
Ready
240 V
208 V
Quick Specs
Welding Amp Range
30–280 A
Rated Output
200 A at 24 VDC, 60% duty cycle
Mild Steel Thickness Range
24 ga.–1/2 in.
Hobart Welding Products
An ITW Welding Company
Sales: 800-626-9420
Service: 800-332-3281
HobartWelders.com
2
Performance Data
Certified by Canadian Standards Association to both Canadian and U.S. Standards.
Note: Running off of generator power is not recommended for the IronMan 240. Operating temperature range: -4° to +104°F (-20° to +40°C)
Rated Output
200 A at 24 VDC,
60% duty cycle
Open Circuit
Voltage
40 VDC
Welding Amp
Range
30–280 A
Dimensions
H: 30 in. (762 mm)
W: 19 in. (483 mm)
D: 40 in. (1,016 mm)
Amperes Input at Rated Load
208 V 240 V KVA KW
57.0 50.8 11.4 7.1
Wire Feed
Speed Range
50–700 ipm
(1.3–17.8 m/min.)
Net Weight
186 lb.
(84 kg)
Control Panel
Open door below
for key information
IronMan 240
240V Wire Feed Welder
30–280 Amp Output
™
1. Infinite Voltage Control
2. Wire Speed Control
3. Power On Indicator Light
4. Diagnostic Indicator Light
Specifications (Subject to change without notice.)
10 20 30 40 50 60 70 80 90 100
% Duty Cycle
Duty Cycle Chart
0
50
100
150
250
200
300
Weld Amperes
3
Protective Cover 770973
Form-fitted, vinyl-laminated, polyester fabric
resists stains and mildew and protects the
finish of your welder.
Reversible V-Groove Drive Rolls
for Mild Steel Wire
235286 .030 /.035 in. (0.8/0.9 mm)
235287 .023 and .045 in. (0.6–1.1 mm)
Reversible V-Knurled Drive Rolls
for Flux-cored Wire
132958 .035 in. (0.9 mm)
132957 .045 in. (1.2 mm)
MIG Gun and Accessories
HR-200 Replacement MIG Gun 284973
Comes in 15 ft. (4.6 m) length with liner for
.023–.045 in (0.6 – 1.1 mm) wire. Gun rated
at 200 amps at 60 percent duty cycle using
CO2 gas or mixed gas.
Contact Tips
(See chart on below)
Nozzles
(See chart below)
Adapter
(See chart below)
Replacement Liners
(See chart below)
Spool Gun and Accessories
SpoolRunner™ 200 Spool Gun 770967
Spool gun with 4-inch spool and 20-foot cable
assembly. Rated at 200 amps at 60 percent
duty cycle. When combined with IronMan 240,
this spool gun welds with .030–.035 inch wire
on 16-gauge to 1/2-inch thick aluminum.
Contact Tips (5 per package)
199387 For .030 in. (0.8 mm) wire.
199388 For .035 in. (0.9 mm) wire.
199389 For .047 in. (1.2 mm) wire.
Nozzle 050622
Standard Replacement Drive Roll
243452 .030/.035 in. (0.8/0.9 mm)
Optional VK Drive Roll
136135 .030–.047 in. (0.8–1.2 mm)
Recommended for running .047 in. (1.2 mm)
wire on SpoolRunner 200.
Item Hobart Package Part #
Contact Tips
.023/.025 in. (0.6 mm) 770174 (5 per package)
.030 in. (0.8 mm) 770177 (5 per package)
.035 in. (0.9 mm) 770180 (5 per package)
.045 in. (1.2 mm) 770183 (5 per package)
Flush Nozzle
1/2 in. (12.7 mm) orifice flush 770544
5/8 in. (16 mm) orifice flush 770405
Tip Adapter 770403
Replacement Liners
.023/.025 in. (0.6 mm) 196139
.030/.035 in. (0.8/0.9 mm) 196139
.035/.045 in. (0.9/1.2 mm) 196140
Accessories
MIG Gun Consumables
HobartWelders.com
© 2020 Hobart and the Hobart logo are trademarks of Illinois Tool Works, Inc.
Trigger lead
Spool gun weld cable
Work cable Workpiece
Spool gun
IronMan 240
Gas hose to gas regulator
240 V power cord
It’s quick and easy to install the SpoolRunner 200 spool gun on the IronMan 240. Just plug the power pin of the spool gun into the feedhead,
and attach the trigger lead. Install the correct wire and gas for the job and it’s ready to go.
Typical Installation for Optional SpoolRunner™ 200 Spool Gun to IronMan™ 240
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Hobart 500574 Owner's manual

Hobart
Brand
Hobart
Model
500574
Category
Welding System
Type
Owner's manual
This manual is also suitable for
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